PROFITABLE FSW SOLUTIONS
Friction stir welding for an optimal production process.
Friction Stir Welding Machines
Strong joints for the industry - with modular Friction Stir Welding Machines, we supply you with reliable FSW complete solutions for automated production.
IN SHIPBUILDING YOU CAN GO BIG
Connect large components in naval engineering.
Welding components: offshore modules, modules and stair tower walls, ship decks, side walls, fright tanks, elevator shafts, yacht structures.
IN AUTOMOTIVE ENGINEERING, YOU WILL STEP UP THE PACE OF YOUR WELDING PROCESS
Wide range of possibilities for the process-safe joining of different materials.
Welding components: Bearing housings, gearbox housings, load floors, side walls, rims, battery boxes, core structures.
IN AVIATION YOU WILL WELD LARGE PARTS WITH FLYING EASE
The challenge for the aerospace industry is to produce as light, strong and cost-effective as possible.
Welding components: Stringer profiles, outer skins, wing components, cargo carriers, connecting consoles, fuel systems, boosters.
IN RAIL VEHICLE CONSTRUCTION YOU CAN SWITCH TO HIGH SPEED
FSW enables better seam qualities and less rework.
Welding components: Main side frames, floor assemblies, side panels, roof assemblies, engine compartments.
IN INDUSTRIAL PLANT CONSTRUCTION YOU CAN THINK BIG
Numerous application areas of the FSW process in industrial plants.
Welding components: Scaffolding, heat sinks, crane components, silos, facade panels.
YOUR BENEFITS - WHY FOOKE FRICTION STIR WELDING MACHINES ARE THE BEST CHOICE
Our know-how for your process:
- Many years of experience in mechanical engineering.
- High vertical range of manufacture including tool development, joining and clamping technology.
- Turnkey solutions from one source.
- Comprehensive, worldwide service and fast help on site.
Your advantages at a glance:
- Detailed consultation in advance.
- Intensive exchange with our FSW engineers.
- Modular machine structure enables individual adaptability of the FSW systems.
- Best possible integration into existing production processes.
- High return of investment.
FRICTION STIR WELDING MACHINES IN ACTION
Customer Projects and Use Cases
Innovative Friction Stir Welding Machine
Aerospace Industry
Our state-of-the-art Friction Stir Welding machine enables precise and material-friendly joining of large-format aluminium sheets into load-bearing structures such as aircraft fuselages – based on a proprietary 5-axis FSW process developed in-house.
This advanced welding technology allows for significant weight reduction – up to 1 kg per metre of aircraft length. The result: drastically reduced kerosene consumption and a measurable contribution to more sustainable and resource-efficient aviation.
Key Advantages at a Glance:
- No sealants required – saves material, cost, and time
- Chipless joining – no drilling swarf, no additional cleaning needed
- Minimal tool wear – longer service life and lower maintenance costs
- Reduced energy consumption – highly efficient, even with large components
- Improved aerodynamics – thanks to flush, smooth weld seams
- No rivet head wear – maintenance-free joints
- Elimination of titanium fasteners – further weight savings
- 100% recyclable longitudinal seam – ideal for lightweight construction
- Significant reduction in fuel consumption – economic and environmental benefit
Our Friction Stir Welding machines are redefining the manufacturing of lightweight structures in the aerospace industry – precise, efficient, and future-ready.
Double-Gantry Friction Stir Welding Machine FSW 50
Commercial Vehicle Manufacturing
When joining truck longitudinal beams, floor panels, and side elements, the FSW 50 stands out with its exceptional process reliability, minimal component distortion, and significantly improved production efficiency. Thanks to its two independent gantries and three separate working zones, the system enables parallel processing of multiple workpieces – resulting in a substantial reduction in cycle times while maintaining consistently high joint quality.
Highlights
- Highly rigid machine structure – for maximum stiffness and minimal deflection, even under heavy loads
- High dynamics and feed rate – ideal for long and large-volume components
- Two gantries, three working zones – for parallel production and maximum machine utilisation
- Specifically designed for commercial vehicle manufacturing – optimal welding of truck structural parts
- Accelerated production processes – shorter cycle times and increased productivity
- Low-distortion weld seams – less rework and greater dimensional accuracy
- Material and energy efficient – no filler materials or welding fumes
- Fully automatable – seamless integration into existing production lines
With the FSW 50, FOOKE offers a highly adaptable Friction Stir Welding solution tailored to the specific demands of vehicle manufacturing – powerful, flexible, and engineered for maximum efficiency.
Floor Structures, Sidewalls, and Roof Assemblies
Railway Vehicle Industry
FOOKE Friction Stir Welding Machines are a trusted solution in the rail vehicle industry for the reliable joining of large aluminium profiles. Our high-performance FSW systems deliver outstanding process stability, precision weld seams, and maximum manufacturing efficiency – even for deep weld applications.
With advanced 5-axis technology and robust machine design, our systems enable friction stir welding depths up to 100 mm – while maintaining excellent seam quality and fully reproducible results. Ideal for modern rail vehicle manufacturing, where structural integrity and lightweight design are essential.
Technical Highlights of FOOKE FSW Machines
- Superior machine rigidity – ensures low deflection and consistent welding quality
- Optimised motion dynamics – for faster cycle times and reduced production costs
- Automated process monitoring – guarantees continuous quality assurance and traceability
- Excellent weld quality – even for high-volume aluminium profiles used in rail vehicle structures
Secure Clamping for Complex Aluminium Components
Our intelligent, adaptable clamping technology guarantees safe and stable positioning of large and complex aluminium components. This ensures repeatable, high-quality welds – even under demanding industrial conditions.
Whether you're welding floor panels, side walls, or roof sections, FOOKE offers the ideal Friction Stir Welding solution for achieving high-strength, low-distortion joints in aluminium-based rail vehicle construction.
Custom Clamping Systems for Maximum Process Reliability
Rail Vehicle Industry
A stable and reproducible Friction Stir Welding (FSW) process starts with correct and secure fixation. At FOOKE, we develop customised clamping systems precisely tailored to your component geometry and process requirements.
These purpose-built fixtures ensure accurate positioning and force-locked clamping of workpieces – even for large or complex aluminium components.
Your Advantages at a Glance
- Maximum process reliability – thanks to distortion-free, controlled component fixation
- Consistently high weld quality – regardless of component size or batch volume
- Reduced post-processing – through dimensionally stable, stress-free weld joints
- Fast setup times – with ergonomic, process-optimised clamping design
With FOOKE’s tailor-made clamping technology, you lay the foundation for a high-quality, cost-efficient, and fully automatable Friction Stir Welding production – perfectly adapted to your specific application.
HIGH-STRENGTH WELDED JOINTS FOR DEMANDING INDUSTRIAL APPLICATIONS
Engineered with FOOKE Friction Stir Welding Machines
Quality „made in Germany“:
this philosophy is consistently followed by FOOKE.
You are a partner of the industry and are facing the challenge of reliably welding large components in constant quality? In that case, the technology of friction stir welding supplies you with the key advantages.
With modular machine systems, FOOKE offers process reliable overall solutions for the automatic manufacturing. We use our know-how and experience as long-time manufacturer of gantry milling machines and from numerous applications in the railway technology, the automotive and the aerospace industry, for the development of innovative machine concepts in the field of FSW.
From individual FSW systems up to a completely new interlinked manufacturing process, we supply overall FSW solutions for the industrial series production. Many years of experience in mechanical engineering, joining technology and our high in-depth production translate into efficient machine concepts, specially tailored to your needs.
Our turnkey solutions guarantee an optimized productivity and a high level of safety and reliability – worldwide. Discover new markets with our innovative FSW solutions!
From process consulting and development to production and commissioning, we carry out all processes for you.
Our tailor-made individual solutions in combination with an established system of standard components, assemblies and clamping concepts, ensure an effective machine concept that you can easily and efficiently use use when you take over.
For optimum parameters for your production, we conduct feasibility studies for your components in our Technology and Demonstration Center in advance.
After the acceptance, we are at your disposal with product support, process optimization, training and service. Fast response times, an extensive spare parts warehouse and worldwide service ensure the productivity of your plant.
YOUR REQUIREMENTS DEFINE OUR SOLUTION
We don’t offer off-the-shelf Friction Stir Welding systems – because your production environment is unique. At FOOKE, every FSW machine is engineered to integrate seamlessly into your specific processes, component geometries, and automation workflows.
A Custom FSW Solution Begins with Understanding Your Production Process
Before we begin designing your Friction Stir Welding (FSW) machine, we conduct a thorough analysis of your complete manufacturing process:
- What materials and alloys are being processed – such as aluminium or titanium?
- How is your production environment structured – manual, semi-automated, or fully integrated?
- What mechanical properties and quality standards must your components meet?
This understanding forms the basis of your dedicated FOOKE FSW engineering team, tailored to your specific industry – whether you're working in aerospace, space technology, shipbuilding, rail transport, or commercial vehicles.
Built for Industry-Specific Challenges.
Our FSW solutions are individually developed to meet the highest demands in:
- Aerospace – high-strength, low-weight welds for fuselage and wing structures
- Space applications – ultra-precise welds for fuel tanks and structural panels
- Shipbuilding – large-scale, corrosion-resistant welds for hull and deck sections
- Rail vehicle construction – seamless joining of aluminium floor panels and side walls
- Commercial vehicle production – fast, distortion-free welding of truck frame components
From Concept to Integration – Fully Engineered FSW Systems
Only once all critical parameters are defined do we begin developing your bespoke Friction Stir Welding system. Throughout the process, we work closely with you to ensure seamless integration and maximum productivity.
Our development team supports you end-to-end:
- From machine design and construction
- Through control system and software integration
- To commissioning, training, service, and long-term support
We deliver a complete turnkey FSW system that’s tailored to your needs – powerful, efficient, and future-ready.
Contact Our
Friction Stir Welding Experts
Looking for the right solution or have questions about your Friction Stir Welding Machine project? Our experienced FSW engineers are here to help – whether it’s a technical enquiry, project consultation or service request.
Feel free to call or email us – we look forward to hearing from you.
You’ll receive a prompt and professional response.
Phone: +49 (0) 2861 / 8009 - 222
Email: info[at]fooke.de
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FAQs: FRICTION STIR WELDING MACHINES BY FOOKE
What Is a Friction Stir Welding Machine?
A Friction Stir Welding (FSW) machine is a specialised system that joins metals in the solid state – without melting. It uses a rotating tool that generates frictional heat, softening the materials locally. The plasticised material is then mechanically stirred and forged together under pressure, creating a high-strength, defect-free weld.
Which Materials Can Be Welded Using a Friction Stir Welding Machine?
Friction Stir Welding machines are primarily used to weld aluminium and its alloys, thanks to their excellent weldability in solid-state processes. However, depending on the machine configuration and tool material, FSW can also be applied to copper, titanium, magnesium, and certain steels.
These applications require tailored machine setups and precise process control to ensure optimal weld quality across different material types.
What Are the Advantages of Friction Stir Welding Compared to Conventional Welding Methods?
Friction Stir Welding (FSW) offers several key benefits over traditional fusion welding processes:
- High-strength, pore-free welds with excellent structural integrity
- Minimal distortion due to the solid-state nature of the process
- No filler materials or shielding gases required – reducing costs and complexity
- Exceptional energy efficiency, making it a sustainable welding solution
- Ideal for thin-walled components and demanding aluminium joints
These advantages make FSW particularly well-suited for industries where precision, strength, and repeatability are critical – such as aerospace, rail, and automotive.
Where Is Friction Stir Welding Typically Used?
Friction Stir Welding (FSW) is commonly used in industries where lightweight and high-strength metal joints are essential. Typical application areas include:
- Aerospace and space technology – for fuselage structures, tanks, and panels
- Automotive and commercial vehicle manufacturing – for chassis components and body parts
- Rail vehicle construction – for floor panels, side walls, and roof sections
- Shipbuilding – for decks, hull sections, and corrosion-resistant structures
FSW is ideal for joining aluminium and other non-ferrous alloys in environments where durability, low distortion, and weight reduction are critical.
Does FOOKE Offer Custom Turnkey Friction Stir Welding Solutions?
Yes – FOOKE develops fully customised Friction Stir Welding (FSW) systems, ranging from compact standalone machines to fully automated, high-volume production lines. Every solution is tailored to your specific components, processes, and integration needs.
Get in touch – we’re happy to advise you!
How Is Quality Assurance Handled in Friction Stir Welding?
Quality assurance in Friction Stir Welding (FSW) is achieved through continuous process monitoring, detailed parameter documentation, and – where required – non-destructive testing (NDT) methods such as ultrasonic inspection or eddy current testing.
This ensures consistently high weld seam quality and full traceability throughout the production process.